Multiple component feed methods and systems

ABSTRACT

Multiple components are selected, conveyed, and measured in a polymerization system. A control system adjusts the system variables to the desired values. Portions of the components can be fed to a pre-contactor before introduction into the polymerization reactor. The catalyst component concentrations and residence times are tightly controlled in the pre-contactor to affect product properties. The pre-contactor can be a single or multiple combinations of a CSTR or plug flow pre-contactors.

This application is a divisional of U.S. patent application Ser. No.11/241,016, filed Sep. 30, 2005, which is herein incorporated byreference in its entirety.

TECHNICAL FIELD

This application relates to the methods and systems for the introductionof multiple components to a polymerization system.

BACKGROUND OF THE INVENTION

In typical polyolefin reaction processes, various components are addedto a polymerization system to begin the polyolefin reaction process.These various components can include olefin feed components, diluentcomponents, and catalyst components.

Upon introduction of the olefin feed components, the diluent components,and the catalyst components into a polymerization reactor, thepolymerization reaction process begins. The polymerization reactiontakes place within the polymerization reactor under a set of reactionconditions. The reaction conditions can include reaction temperature,reaction pressure, reactor residence time, and concentrations of thevarious components within the reactor, such as reactor solids, ethylene,hexene, hydrogen, co-catalysts, antistatic agents, electron donors, andinerts, such as ethane and propane.

It is often desirable to produce polyolefins having certain physical andmechanical properties, depending upon the application and market inwhich the polyolefin is to be used. These markets can include, forexample, blow molding, injection molding, rotational molding, film,drums, and pipe. Some physical properties that can be important,depending on the product requirement and application, are molecularweight, molecular weight distribution, density, crystallinity, andrheology. Some mechanical properties that can be important, depending onthe product requirement and application, are modulus, tensileproperties, impact properties, stress relaxation, creep, and elongation.However, obtaining polyolefins with consistent desired properties isdifficult to accomplish. The properties of the polyolefin producedwithin the polymerization system can be affected by the reactionconditions under which the reaction takes place, including reactorconcentrations. Consequently, specific control of the various componentsintroduced into the reactor, including catalyst components, must oftenbe precisely measured and monitored.

The rate at which catalyst components are added to the reactor canaffect the physical and mechanical properties of the polyolefin beingproduced within the reactor, and therefore is an important factor tocontrol and monitor. Conventional methods of adding catalyst componentsto reactor systems may introduce possible error into the reactionprocess, resulting in the production of off-specification product. Forexample, in at least one conventional polyolefin reaction system,catalyst components are fed to the polymerization reactor using ballcheck feeders. Ball check feeders typically include a rotating cylinderhaving a cavity on one side of the cylinder. The cavity fills withcatalyst components and empties the catalyst components into the reactorafter each 180° rotation of the cylinder. However, the amount ofcatalyst component that fills the cavity during each rotation of thecylinder may be inconsistent, resulting in inconsistent feed of catalystcomponents to the reactor. Inconsistent feed of catalyst components (aswell as other components) to the reactor can cause inconsistentoperation and control of the polymerization reaction process, resultingin highly variable production rates and production of product outsidethe desired specification limits.

Despite existing systems and methods to control the feed of catalyst andpolymer components to polymerization systems, a need exists for improvedsystems and methods for controlling the introduction of multiplecomponents to a polymerization reactor. Further, a need also exists forimproved systems and methods for combining multiple components in apolymerization system. Yet another need exists for improved systems andmethods of feed control for a catalyst component in a polymerizationprocess. Another need exists for improved systems and methods to producea polymer.

SUMMARY OF INVENTION

In view of the foregoing, an embodiment of the present inventionprovides a method for the introduction of multiple components into apolymerization system. The method of introducing the multiple componentsincludes adding at least one polymerization catalyst component, at leastone activator compound component, and at least one co-catalyst componentinto the polymerization system at a controlled rate. Portions of some orall of the components are contacted in at least one pre-contactor andthen directed from the pre-contactor to at least one polymerizationreactor. Remaining portions of the components that were not sent to thepre-contactor are also directed to the at least one polymerizationreactor. The remaining portions of the components bypass thepre-contactor.

In an aspect, the step of adding the components into the polymerizationsystem at a controlled rate further includes selecting a desired flowrate for each component and conveying the components into thepolymerization system at an actual flow rate. The actual flow rate foreach component is then measured and adjusted to substantially equal thedesired flow rate.

In another embodiment of the present invention, a method for theintroduction of multiple components into a polymerization system isprovided that includes adding at least one polymerization metallocenesolution component, at least one treated solid oxide compound component,and at least one aluminum alkyl component into the polymerization systemat a controlled rate. Portions of some or all of the components arecontacted in at least one plug flow pre-contactor and then directed toat least one polymerization reactor. Remaining portions of thecomponents are also directed to at least one polymerization reactor. Theremaining portions of the components bypass the pre-contactor.

In an aspect, the step of adding the components into the polymerizationsystem at a controlled rate further includes selecting a desired flowrate for each component and conveying the components into thepolymerization system at an actual flow rate. The actual flow rate foreach component is then measured and adjusted to substantially equal thedesired flow rate.

In another embodiment of the present invention, a system forintroduction of multiple components into a polymerization system isprovided that includes means for adding at least one polymerizationcatalyst component, at least one activator compound component, and atleast one co-catalyst component into the polymerization system at acontrolled rate. The system also includes a means for contactingportions of some or all of the components in at least one pre-contactorand a means for directing output from the pre-contactor to at least onepolymerization reactor. The system further includes a means fordirecting remaining portions of the components that were not sent to thepre-contactor to the at least one polymerization reactor. The means foradding the components into the polymerization system at a controlledrate further include a means for selecting a desired flow rate for eachcomponent; a means for conveying the components into the polymerizationsystem at an actual flow rate; a means for measuring the actual flowrate for each component; and a means for adjusting the actual flow ratefor each component to substantially equal the desired flow rate.

In another embodiment of the present invention, a system forintroduction of multiple components into a polymerization system isprovided. The system for introducing multiple components includes ameans for adding at least one polymerization metallocene solutioncomponent, at least one treated solid oxide compound component, and atleast one aluminum alkyl component into the polymerization system at acontrolled rate. The means for adding the components can be used toindividually add each component or can be used to add more than onecomponent at a time to the polymerization system. The system alsoincludes a means for contacting portions of some or all of thecomponents in at least one plug flow pre-contactor and means fordirecting output from the pre-contactor to at least one polymerizationreactor that bypass the pre-contactor. The system further includes ameans for directing remaining portions of the components that were notsent to the pre-contactor to the at least one polymerization reactor.

In an aspect, the means for adding the components into thepolymerization system at a controlled rate further include a means forselecting a desired flow rate for each component and a means forconveying the components into the polymerization system at an actualflow rate. The system further includes a means for measuring andadjusting the actual flow rate for each component to substantially equalthe desired flow rate.

In another embodiment of the present invention, a tangible,machine-readable media is provided that includes code adapted to controlthe concentration of at least one catalyst component in a mixture in apre-contactor vessel to form a polyolefin in a polymerization reactorand code adapted to read measured values of concentrations and residencetimes in the pre-contactor vessel. The machine-readable media alsoincludes code adapted to determine the amount of at least one catalystcomponent to add to the vessel based on the measured values and codeadapted to determine the amount of any catalyst component to bypass thepre-contactor vessel.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 illustrates an exemplary polymerization system for introducingmultiple reaction components into a reactor system in accordance withvarious aspects of the invention;

FIG. 2 illustrates an exemplary embodiment of the reactor system of FIG.1;

FIG. 3 illustrates an exemplary method for introducing multiplecomponents into the polymerization system of FIG. 1; and

FIG. 4 illustrates an exemplary method for adding multiple components tothe polymerization system at a controlled rate within the method of FIG.3.

DETAILED DESCRIPTION OF EMBODIMENTS

During the production of polyolefins, various components are typicallymixed together or reacted with each other within a reactor vessel. Thevarious components can be separately added directly to the reactor, orsome or all of the various components can be mixed by another device orprocess prior to being added to the reactor. In general, the inventionprovides systems and methods for controlling the introduction ofmultiple components to a polymerization reactor. In an aspect of theinvention, a method facilitates controlling the introduction of multiplecomponents to the polymerization reactor. In another aspect of theinvention, a method facilitates combining multiple components to thepolymerization reactor. Another aspect of the invention facilitates amethod of feed control for a catalyst component in the polymerizationprocess. Yet another aspect of the invention facilitates a system forproducing a polyolefin.

Turning now to FIGS. 1 and 2, an exemplary embodiment of apolymerization system 100 includes a reactor system 101, apolymerization catalyst component 102, an activator compound component104, a co-catalyst component 106, and a diluent component 108. Thepolymerization system 100 of this invention also includes a means forfeed and measure 110 for the polymerization catalyst component 102; ameans for feed and measure 112 for the activator compound component 104;a means for feed and measure 114 for the co-catalyst component 106; anda means for feed and measure 116 for the diluent component 108. Theoperability of the polymerization process is improved by measuring someor all of the catalyst components that are fed to the polymerizationreactor 118. Precise measuring of the catalyst components also minimizesthe potential for catalyst leakage or misdirected catalyst flow.

In an aspect, the means for feed and measure 110 for the polymerizationcatalyst component 102 include a means for adding the polymerizationcatalyst component 102 to the polymerization system 100 at a controlledrate. In another aspect, the means for feed and measure 110 for thepolymerization catalyst component 102 can include a polymerizationcatalyst addition system configured to add the polymerization catalystcomponent 102 to the polymerization system 100 at a controlled rate.

In an aspect, the means for feed and measure 112 for the activatorcompound component 104 include a means for adding the activator compoundcomponent 104 to the polymerization system 100 at a controlled rate. Inanother aspect, the means for feed and measure 112 for the activatorcompound component 104 can include an activator compound addition systemconfigured to add the activator compound component 104 to thepolymerization system 100 at a controlled rate.

In an aspect, the means for feed and measure 114 for the co-catalystcomponent 106 include a means for adding the co-catalyst component 106to the polymerization system 100 at a controlled rate. In anotheraspect, the means for feed and measure 114 for the co-catalyst component106 can include a co-catalyst addition system configured to add theco-catalyst component 106 to the polymerization system 100 at acontrolled rate.

In an aspect, the means for feed and measure 116 for the diluentcomponent 108 include a means for adding the diluent component 108 tothe polymerization system 100 at a controlled rate. In another aspect,the means for feed and measure 116 for the diluent component 108 caninclude a diluent addition system configured to add the diluentcomponent 108 to the polymerization system 100 at a controlled rate.

The reactor system 101 can be any reactor system suitable for carryingout a polymerization process to produce a desired polyolefin product. Asshown in FIG. 2, the reactor system 101 of this invention includes apolymerization reactor 118, a pre-contactor 120, and a by-pass 122.

The polymerization reactor 118 can be any reactor unit in which apolymerization reaction can occur such as, for example, a continuousstirred tank reactor (CSTR), a slurry loop reactor, a batch reactor, agas phase reactor, an autoclave reactor, a tubular reactor, a multi-zonereactor, a fluidized bed reactor, a fixed bed reactor, a stirred bedreactor, or a stirred fluidized bed reactor. In an embodiment, thepolymerization reactor 118 is a slurry loop reactor. Other suitabletypes of reactors will be apparent to those of skill in the art and areto be considered within the scope of the present invention.

When a slurry loop reactor is used, the polymerization reactor 118 ofthis invention can be a loop of pipe having a nominal outside diameterof between 12 and 36 inches. The polymerization reactor 118 can beoriented horizontally or vertically. The polymerization reactor 118 canhave any number of reactor legs, such as between 2 and 16 legs;alternatively, between 2 and 12 legs; alternatively, between 2 and 8legs; or alternatively, between 2 and 6 legs. The polymerization reactor118 volume is not limited by this invention. The polymerization reactor118 volumes can range from about 1,000 gallons to about 80,000 gallons.The contents within the polymerization reactor 118 are circulatedthroughout the polymerization reactor 118 in the form of a slurry. Theslurry includes one or more of the following: a hydrocarbon, a diluent,a catalyst, and a polymer. The slurry can be circulated by an urgingmeans (not shown). The urging means can be any means suitable forcirculating the slurry throughout the reactor 118 such as, for example,an axial flow pump, a mixed flow pump, a centrifugal pump, a positivedisplacement pump, or any combination thereof. In an embodiment, theurging means is one or more axial flow pumps. Homopolymers andco-polymers of polyolefins, such as polyethylene and polypropylene, canbe produced in the polymerization reactor 118. Variables important tothe operation of the polymerization reactor 118 can be monitored andcontrolled by an interface. Common interfaces include DCS (distributedcontrol system), PLC (programmable logic controller), and a NeuralNetwork. Variables important to reactor operation include productionrates, catalyst feed rates, temperatures, pressures, flow rates,concentrations, and the like. For example, residence time in thepolymerization reactor 118 can be limited to a predefined time, and thesolids concentration for each component can be maintained. Operatingconditions can include, but are not limited to, residence time,temperature, pressure, chemicals concentration, solids concentration,and combinations thereof. Maintaining relatively high reactor solidsconcentration and increasing polyethylene production because of theconsistent catalyst feeding can improve the operation of thepolymerization reactor 118. For example, residence time can becontrolled to within a range of approximately 20 minutes to 3 hours,temperature can be controlled to within a range of approximately150-230° F. (66-110° C.), pressure can be controlled to within a rangeof approximately 500-800 pounds per square inch (34-55 bar), and solidsconcentration can be controlled to within a range of approximately 30-75weight %. The polymerization reactor 118, which can be a slurry loopreactor, is described in greater detail in U.S. Pat. Nos. 6,420,497;6,239,235; 5,565,175; 5,565,174; 5,455,314; and 4,613,484, thedisclosures of which are herein incorporated in their entirety byreference.

As depicted in FIG. 2, the reactor system 101 further includes thepre-contactor 120. The pre-contactor 120 is designed to contact one ormore selected components prior to introducing the selected componentsinto the polymerization reactor 118. The selected components that areintroduced to the pre-contactor 120 are chosen from the polymerizationcatalyst component 102, the activator compound component 104, theco-catalyst component 106, the diluent component 108, and combinationsthereof and can include any amount of any of these components 102, 104,106, and 108.

The pre-contactor 120 can be any type of vessel suitable for contactingthe one or more selected components 102, 104, 106, and 108 prior tointroducing the selected components 102, 104, 106, and 108 into thepolymerization reactor 118, such as, for example, a continuous stirredtank reactor (CSTR) or a plug flow reactor. The pre-contactor 120 cancontain an agitation means (not shown) for mixing the one or moreselected components 102, 104, 106, and 108 together or otherwiseagitating the one or more selected components 102, 104, 106, and 108.The agitation means can include, but is not limited to, one or moreimpellers, a rotating element, a mixer, a vibrating device, or anycombination thereof.

In an embodiment of the present invention, the pre-contactor 120 is acontinuous stirred tank reactor (CSTR). When the pre-contactor 120 is aCSTR, the components are mixed with the assistance of the agitationmeans. The contents have a residence time distribution (rtd) within thepre-contactor 120. For example, in a typical single CSTR, the decay rateis about 60 to about 70% complete at one residence time, about 80 toabout 90% complete at two residence times, and about 92 to about 98%complete at three residence times. In other words, about 60 to about 70%of the contents in the pre-contactor 120 remain for +/− one residencetime; about 80 to about 90% remain for +/− two residence times; andabout 92 to about 98% for +/− three residence times. Alternatively, thedecay rate can be about 62 to about 65% at one residence time, about 85to about 87% for two residence times, and about 94 to about 96% at threeresidence times. Multiple CSTRs can give a narrower rtd. For example,infinite CSTRs in series simulate the rtd as in a batch reactor. In analternative embodiment, the pre-contactor 120 is a plug flow typevessel. The particles within the plug flow type reactor 120 all haveapproximately the same residence time with little or no lateral mixing.In yet another embodiment, the pre-contactor 120 includes at least oneplug flow type vessel and at least one CSTR arranged in series. Oneskilled in the art will recognize other arrangements are possible withsingle or multiple CSTRs and plug flow reactors, and are included in thescope of the present invention.

In some embodiments, the polymerization system 100 includes at least twopolymerization reactors 118. In an aspect, the polymerization reactors118 are arranged in a series configuration. In another aspect, thepolymerization reactors 118 are arranged in a parallel configuration.

Operating conditions for the pre-contactor 120 can be monitored andcontrolled. Predefined amounts of components 102, 104, 106, and 108introduced into the pre-contactor 120 can be monitored and controlledprior to introduction into the pre-contactor 120, and any mixing oragitation of the components 102, 104, 106, and 108 can be controlledwithin a range of selected conditions. Factors that can be controlled inthe pre-contactor 120 include residence time, temperature, pressure,concentration, and combinations thereof of the one or more selectedcomponents 102, 104, 106, and 108. Control of these factors can affectthe properties of the polyolefin later produced within thepolymerization reactor 118.

Residence time, which can also be referred to as contact time, withinthe pre-contactor 120 can be controlled, for example, by controlling therate of flow of the diluent component 108 into the pre-contactor 120.The residence time within the pre-contactor 120 can be any amount oftime suitable for thoroughly contacting the one or more selectedcomponents, such as, for example, from about 1 second to about severalhours. In some embodiments, the residence time ranges from about 1second to about 300 minutes; alternatively, from about 1 second to 200minutes; alternatively, from about 1 second to about 100 minutes;alternatively, from about 1 second to about 60 minutes; oralternatively, from about 1 second to about 30 minutes.

The residence time can be adjusted prior to introduction of thecomponents 102, 104, 106, and 108 to the polymerization reactor 118 inresponse to product performance and reactor operability. Control of thepolymerization reactor 118 and the quality of the polyolefin product canbe improved as a result of the increased precision in measurement andcontrol of catalyst feed to the polymerization reactor 118. Thecomponents 102, 104, 106, and 108 can completely or partially bypass thepre-contactor 120 to increase precision and control of the catalystfeed. In other cases superior catalyst and product performance can beachieved by contacting some or all of the components 102, 104, 106, and108 prior to introduction into the polymerization reactor 118 aspreviously described.

When a plug flow pre-contactor is used, the streams entering thepre-contactor 120 can enter at different locations in the pre-contactor120. Some components 102, 104, 106, and 108 can enter at the front orbeginning and others can be spaced throughout the length of thepre-contactor 120. By staging the components 102, 104, 106, and 108throughout the plug flow pre-contactor 120, the residence time of eachcomponent 102, 104, 106, and 108 can be tailored for productperformance. As an example, one method can be to add the one or multiplepolymerization catalyst components 102 at the entrance of the plug flowpre-contactor 120, add the activator compound component 104, theco-catalyst component 106, and combinations thereof downstream of theentrance. Polymerization catalyst components 102, activator compoundcomponents 104, and co-catalyst components 106 can remain in thepre-contactor 120 in step 310 from less than one second to several hoursbefore contacting the other components 102, 104, 106, and 108. Asanother example, the polymerization catalyst components 102 can also bestaged with the activator compound component 104 followed by thepolymerization catalyst component 102, followed by the co-catalystcomponent 106, followed by the polymerization catalyst component 102,and then followed by the same or different co-catalyst component 106.

In some embodiments, the system 100 can have up to 6 differentpolymerization catalyst components 102 staged with different co-catalystcompounds 106 downstream of each of the polymerization catalystcomponents 102. Alternatively, the system 100 can have up to fourdifferent polymerization catalyst components 102. Alternatively, thesystem can have up to three different polymerization catalyst components102. Those skilled in the art will recognize other applications of theinvention in accordance with various embodiments of the invention. Forexample, the pre-contactor 120 can be a CSTR, a plug flow, two or moreCSTRs in series, CSTR followed by a plug flow, or any other combination.

Many methods to control the temperature in the pre-contactor 120 arepossible, including by direct and indirect heating. Temperature controlcan be an important factor in chemical reactions. Because of thedifferent reaction rates, paths, and diffusivities that vary withreaction temperature, the reaction temperature needs to be heldrelatively constant to consistently produce reaction products havingsimilar properties. Suitable means of controlling the pre-contactor 120temperature will be apparent to those of ordinary skill in the art andare to be considered within the scope of the present invention.

The concentration of components 102, 104, 106, and 108 in thepre-contactor 120 can be varied and adjusted to affect the reaction, theproduct quality, or the reactor operation. The reaction rate can beaffected by having a higher or lower concentration of one or more of thecomponents 102, 104, 106, and 108 in the pre-contactor 120. A certainratio of components 102, 104, 106, and 108 in the pre-contactor 120 cangive optimal catalyst performance, product quality, and reactoroperability. Furthermore, a ratio of one or more of the components 102,104, 106, and 108 in the pre-contactor 120 in relation to the feeddirectly to the reactor 118 can affect the reactor operability. Thereaction extent can be affected by having a higher or lowerconcentration of one or more of the components 102, 104, 106, and 108 inthe pre-contactor 120. The components efficiencies can be affected byhaving a higher or lower concentration of some or all of the components102, 104, 106, and 108 in the pre-contactor 120.

As also shown in FIG. 2, the reactor system 101 further includes apre-contactor bypass 122. The pre-contactor bypass 122 is designed todirect some or all of the components 102, 104, and 106 directly to thepolymerization reactor 118, without first being sent to thepre-contactor 120. The pre-contactor bypass 122 allows for the contactof some or all of each component 102, 104, and 106 to take place in thepolymerization reactor 118 instead of in the pre-contactor 120. In anaspect, the components 102, 104, and 106 can be added individually tothe polymerization reactor 118; or alternatively, one of more of thecomponents 102, 104, and 106 can be combined prior to adding thecomponents 102, 104, and 106 to the polymerization reactor 118. Theproperties of the polyolefin product and catalyst performance can becontrolled by adjusting the amounts of components 102, 104, and 106directed to the pre-contactor 120 versus the amounts of components 102,104, and 106 sent directly to the polymerization reactor 118 via thepre-contactor bypass 122. The output from the pre-contactor 120 can havedifferent properties, such as a particular ratio of components, than thecomponents 102, 104, and 106 that are sent directly to thepolymerization reactor 118. The properties that can be affected bysending the components 102, 104, and 106 to the pre-contactor 120 aredescribed herein. The pre-contactor bypass 122 can be any vessel ordevice suitable for directing the flow of some or all of the components102, 104, and 106 directly to the polymerization reactor 118. In anembodiment, the pre-contactor bypass 122 is pipe or tubing.

The means for feed and control 110, 112, 114, and 116 measure andcontrol the rates at which the components 102, 104, 106, and 108 areintroduced into the polymerization system 100. The means for feed andcontrol 110, 112, 114, and 116 can be any device suitable for preciselymeasuring and controlling the rates at which the components 102, 104,106, and 108 are introduced into the polymerization system 100, such as,for example, a flow meter, a pump, or a combination thereof. In anembodiment, the means for feed and control 102, 104, 106, and 108 are acombination flow meter and pump. The pump can be any pump suitable forprecisely measuring and controlling the rates at which the components102, 104, 106, and 108 are introduced into the polymerization system100. In some embodiments, the pump is a positive displacement-type pump.In some embodiments, the pump can be a syringe pump. The flow meter canbe any flow meter suitable for precisely measuring and controlling therates at which the components 102, 104, 106, and 108 are introduced intothe polymerization system 100, such as, for example, a thermal mass flowmeter or a volumetric flow meter such as an orifice-type,diaphragm-type, or a level-type meter. In some embodiments, the flowmeter is a mass flow meter. More specifically, in some embodiments, theflow meter is a coriolis-type meter adapted to measure a variety of flowtypes from a positive displacement-type pump. Any combination of meansfor feed and control 110, 112, 114, and 116 can be used for eachcomponent 102, 104, 106, and 108, and it is not necessary that the sametype of means for feed and control is used for every component 102, 104,106, and 108. For example, means for feed and control 110 for thecatalyst component 102 can be a mass flow meter, while the means forfeed and control 112 for the activator compound component 104 can be apump.

The polymerization catalyst component 102 is provided to thepolymerization system 100 as the active compound for a polymerizationcatalyst. The polymerization catalyst component 102 can be any catalystcomponent suitable for olefin polymerization, such as, for example, achrome oxide catalyst, a chrome silyl catalyst, a Zeigler-Nattacatalyst, a metallocene catalyst, a phenoxyimine catalyst, and aphosphated aluminum catalyst. Additionally, the composition of thecatalyst component 102 can include an additional compound such astitanium. In an exemplary embodiment, the polymerization catalystcomponent 102 is a metallocene solution. In some aspects, thepolymerization catalyst component 102 is a metallocene solution havingthe following general equation:(X(1))(X(2))(X(3))(X(4))M(1);In this equation, M(1) is selected from the group consisting oftitanium, zirconium, and hafnium. (X(1)) is independently selected fromthe group consisting of cyclopentadienyl, indenyls, fluorenyls,substituted cyclopentadienyls, substituted indenyls, and substitutedfluorenyls. Substituents on the substituted cyclopentadienyls,substituted indenyls, and substituted fluorenyls of (X(1)) are selectedfrom the group consisting of aliphatic groups, cyclic groups,combinations of aliphatic and cyclic groups, silyl groups, alkyl halidegroups, halides, organometallic groups, phosphorus groups, nitrogengroups, silicon, phosphorus, boron, germanium, hydrogen, andcombinations thereof. At least one substituent on (X(1)) can be abridging group that connects (X(1)) and (X(2)) (X(3)) and (X(4)) areindependently selected from the group consisting of halides, aliphaticgroups, substituted aliphatic groups, cyclic groups, substituted cyclicgroups, combinations of aliphatic groups and cyclic groups, combinationsof substituted aliphatic groups and cyclic groups, combinations ofaliphatic groups and substituted cyclic groups, combinations ofsubstituted aliphatic groups and substituted cyclic groups, amidogroups, substituted amido groups, phosphido groups, substitutedphosphido groups, alkyloxide groups, substituted alkyloxide groups,aryloxide groups, substituted aryloxide groups, organometallic groups,substituted organometallic groups, and combinations thereof. (X(2)) isselected from the group consisting of cyclopentadienyls, indenyls,fluorenyls, substituted cyclopentadienyls, substituted indenyls,substituted fluorenyls, halides, aliphatic groups, substituted aliphaticgroups, cyclic groups, substituted cyclic groups, combinations ofaliphatic groups and cyclic groups, combinations of substitutedaliphatic groups and cyclic groups, combinations of aliphatic groups andsubstituted cyclic groups, combinations of substituted aliphatic groupsand substituted cyclic groups, amido groups, substituted amido groups,phosphido groups, substituted phosphido groups, alkyloxide groups,substituted alkyloxide groups, aryloxide groups, substituted aryloxidegroups, organometallic groups, substituted organometallic groups, andcombinations thereof. Substituents on (X(2)) are selected from the groupconsisting of aliphatic groups, cyclic groups, combinations of aliphaticgroups and cyclic groups, silyl groups, alkyl halide groups, halides,organometallic groups, phosphorus groups, nitrogen groups, silicon,phosphorus, boron, germanium, hydrogen, and combinations thereof. Atleast one substituent on (X(2)) can be a bridging group that connects(X(1)) and (X(2)).

Depending upon the desired properties of the polyolefin (e.g.,polyethylene) to be produced within the polymerization reactor 118, anynumber of catalyst components 102 can be used within the system 100. Insome embodiments, between one and six catalyst components 102 areutilized; alternatively, between one and four catalyst components 102are utilized; and alternatively, between one and three catalystcomponents 102 are utilized.

The activator compound component 104 is provided to the polymerizationsystem 100 for the activation, conversion, or reduction of the catalystcomponent 102 to the active state for polymerization. The activatorcompound component 104 can be any activator compound component suitablefor activation, conversion, or reduction of the catalyst component 102to the active state for polymerization, such as, for example, a treatedsolid oxide, borates and methyl alumina oxane. In an exemplaryembodiment, the activator compound component 104 is a treated solidoxide. More particularly, in some embodiments, the activator compoundcomponent 104 is a super solid acid (SSA) initiator. Other suitableactivator compound components 104 will be apparent to those of skill inthe art and are to be considered within the scope of the presentinvention.

In another example, one component 102 or 104 can be impregnated withanother component 102 or 104, or otherwise combined with anothercomponent 102 or 104, such as impregnating a polymerization catalystcomponent 102 with an activator compound component 104. In an exemplaryembodiment, the metallocene component 102 can be impregnated with anactivator compound component 104. For such instances, the combinedcomponents 102 and 104 can be referred to as a single component, and oneor more of the impregnated components can be omitted from thedescription herein.

The co-catalyst component 106 is provided to the polymerization system100 as an alkylator, electron donor, or for reduction of the catalystcomponent 102 or specifically as the active metal species of thecatalyst component 102. The co-catalyst component 106 can be anyco-catalyst component suitable as an alkylator, electron donor, or forreduction, such as, for example, trimethylaluminum, triethylaluminum(TEAl), tripropylaluminum, diethylaluminum ethoxide, tributylaluminum,diisobutylaluminum hydride, triisobutylaluminum hydride,triisobutylaluminum (TiBAl), trihexylaluminum, and diethylaluminumchloride. In an exemplary embodiment, the co-catalyst component 106 isTEAl or TiBAl. In an aspect, the co-catalyst component 106 can includeat least one aluminum alkyl component. The polymerization system 100 caninclude any number of co-catalyst components 106. In some embodiments,the polymerization system 100 includes one or two co-catalyst components106. The co-catalyst component 106 can also be a mixture of any of thedifferent types of co-catalyst components set forth herein. For example,TEAl and TiBAl can both be added to the polymerization system 100 to actjointly as the co-catalyst component 106. The TEAl and TiBAl can bepremixed, such as in the pre-contactor 120, and added to thepolymerization reactor 118 together, or they can be fed directly to thepolymerization reactor 118 individually as separate feed streams, or acombination thereof.

The diluent component 108 is provided to the system 100 to control theconcentration of the various components 102, 104, and 106 within thesystem 100. For example, the concentrations of the various components102, 104, 106 can be increased by decreasing the volume of the diluentcomponent 108 added to the system 100. Similarly, the concentrations ofthe various components 102, 104, 106 can be decreased by increasing thevolume of the diluent component 108 added to the system 100. The diluentcomponent 108 can be any diluent component suitable for use in thereactor system 100, such as, for example, propane, isobutane, pentane,hexane, heptane, or octane. When the polymerization process is used toproduce polypropylene, unreacted propylene can also be used as thediluent component 108. In an exemplary embodiment, the diluent component108 is isobutane. Other suitable diluent components will be apparent tothose of skill in the art and are to be considered within the scope ofthe present invention.

The diluent component 108 and each of the components 102, 104, 106 aredelivered to the system 100 from a source. The source can be a run tank,storage tank, mix tank, flow pipe, mud pot, or another device, system orprocess that can deliver a suitable amount of the respective diluentcomponent 108, polymerization catalyst component 102, or other component104, 106 for producing a desirable property in the polyolefin to beproduced by the system 100. For example, the diluent component 108 canbe delivered to and stored in a run tank until called upon by the system100. When the system 100 calls upon an amount of diluent component 108,an associated feed pump (not shown) can be activated to deliver theamount of diluent component 108 from the run tank to another part of thesystem 100. Those skilled in the art will recognize that a conventionalrun tank and feed pump combination can be used in accordance withvarious aspects of the invention to store and deliver sufficient amountsof the diluent component 108 and each of the components 102, 104, 106,when called upon by the system 100.

Referring now to FIGS. 3 and 4, a method 300 of introducing multiplecomponents into the polymerization system 100 is provided. The method300 includes adding the components 102, 104, 106, and 108 to thepolymerization system 100 at a controlled rate (step 305) and contactingportions of some or all of the components 102, 104, 106, and 108 in thepre-contactor 120 (step 310). Portions of some or all of the components102, 104, 106, and 108 from the pre-contactor 120 are then directed tothe polymerization reactor 118 (step 315), along with directing anyremaining portions of the components 102, 104, 106, and 108 that werenot directed to the pre-contactor 120 in step 310.

In step 305 of method 300, the components 102, 104, 106, and 108 areadded to the polymerization system 100 at a controlled rate. In anexemplary embodiment, the step 305 of adding the components 102, 104,106, and 108 to the polymerization system 100 at a controlled rateincludes adding the polymerization catalyst component 102, the activatorcompound component 104, the co-catalyst component 106, and the diluentcomponent 108 at a controlled rate by the respective means for feed andcontrol 110, 112, 114, and 116.

Turning now to FIG. 4, the step 305 of adding the components 102, 104,106, and 108 to the polymerization system 100 at a controlled rateincludes selecting a desired flow rate for each component 102, 104, 106,and 108 (step 405) and conveying the components 102, 104, 106, and 108at an actual flow rate into the polymerization system 100 (step 410). Anactual flow rate for each component 102, 104, 106, and 108 is measured(step 415) and adjusted for each component 102, 104, 106, and 108 tomatch the desired flow rate (step 420).

In step 405, the desired flow rates of the components 102, 104, 106, and108 can affect the performance of the catalyst component 102, reactor118 operability, and the physical and mechanical properties of thepolyolefin product. Catalyst performance criteria that can be affectedby the desired flow rates of the components 102, 104, 106, and 108include, for example, activity, productivity, melt index potential,comonomer incorporation, and combinations thereof. Reactor operabilitycriteria that can be affected by the desired flow rates of thecomponents 102, 104, 106, and 108 include, for example, resistance toloss in heat transfer in the reactor, bulk density of the polyolefin inthe reactor, solids formation, production rate, and combinationsthereof. Physical properties of the polyolefin product that can beaffected by the desired flow rates of the components 102, 104, 106, and108 include, for example, shear responses and ratios at different shearrates that can include 0, 0.1, and 100/second; molecular weight;molecular weight distribution; density; crystallinity; and combinationsthereof. Mechanical properties of the polyolefin product that can beaffected by the desired flow rates of the components 102, 104, 106, and108 include, for example, responses in creep tests, stress relaxation,tau eta, tensile at yield and break, elongation at yield and break,secant moduli that can include 0.1 and 2%, tensile (Youngs, elongation)modulus, storage and loss moduli, environmental stress crack growth,PENT, and combinations thereof.

The desired flow rates of the components 102, 104, 106, and 108 can beselected and set using any suitable technique for measuring flow rates.For example, the desired flow rates of the components 102, 104, 106, and108 can be selected based upon ratios of the components 102, 104, 106,and 108; composition amounts; mass flow rates; or volumetric flow rates.The desired flow rates can be entered into a process control system,such as, for example, a Distributed Control System (DCS), a ProgrammableLogic Controller (PLC), or a Neural Network. These process controlsystems work to maintain the desired flow rate in an acceptable range.

In step 410, the components 102, 104, 106, and 108 are conveyed into thepolymerization system 100 at an actual flow rate by the respective meansfor feed and control 110, 112, 114, and 116 at an actual flow rate foreach component 102, 104, 106, and 108. As described previously, themeans for feed and control 110, 112, 114, and 116 can include, forexample, a flow meter, a pump, or a combination thereof.

In step 415, the actual flow rate of each component 102, 104, 106, and108 into the polymerization system 100 can be measured by the respectivemeans for feed and control 110, 112, 114, and 116 using any of thetechniques previously described. In an embodiment, the flow rates of thecomponents 102, 104, 106, and 108 are measured as mass flow rates.Various combinations of measurement are possible for the variouscomponents 102, 104, 106, and 108 depending upon the type of component,chemical compatibility of the component, and the desired quantity andflow rate of the component.

Finally, in step 420, the actual flow rate of each component 102, 104,106, and 108 into the polymerization system 100 is adjusted as necessaryto match the desired flow rate. The actual flow rate of each component102, 104, 106, and 108 is compared to the desired flow rate as selectedin step 405, and adjustments are made to the actual flow rate of eachcomponent 102, 104, 106, and 108 so that the actual flow rates anddesired flow rates are substantially equal. In an embodiment, anoperator selects set points for the desired flow rates of step 305, anda control system maintains the actual flow rates at rates that aresubstantially equal to the desired flow rates. The means for feed andcontrol 110, 112, 114, and 116 provide precise fluid control measurementand flow control for the respective component 102, 104, 106, and 108 tobe provided and introduced in method 300.

Each of the means for feed and control 110, 112, 114, and 116 in step305 is adapted to receive a command, such as a user input or signal. Thecommand includes instructions to operate or otherwise adjust the flowrate of the components 102, 104, 106, and 108 with the means for feedand control 110, 112, 114, and 116 in step 305. In some embodiments, aprocessor-based device (not shown) can be associated with a means forfeed and control 110, 112, 114, and 116 to measure, select, determine orotherwise adjust predefined amounts, feed rates, and other operatingproperties of a component 102, 104, 106, and 108 being introduced,transmitted, or delivered by a means for feed and control 110, 112, 114,and 116 in step 305. For example, a feedback control device (not shown)can be installed downstream from a means for feed and control 110, 112,114, and 116 in step 305 to monitor a feed rate of the component 102,104, 106, and 108, and to transmit a command signal to the means forfeed and control 110, 112, 114, and 116 in step 305 depending upon thefeed rate of the particular component 102, 104, 106, and 108 to thereactor 118, the pre-contactor 120, or another portion of the method300. A command signal can be sent to the means for feed and control 110,112, 114, and 116 in step 305 for the first component 102, 104, 106, and108 in response to the feed rate of the second component 102, 104, 106,and 108. Alternatively, the command signal can be sent to the means forfeed and control 110, 112, 114, and 116 in step 305 for the firstcomponent 102, 104, 106, and 108 in response to the feed rate of thefirst component 102, 104, 106, and 108. Each means for feed and control110, 112, 114, and 116 in step 305 can implement the command signal toadjust the feed rate of the respective component 102, 104, 106, and 108accordingly.

Step 310 of method 300 includes optionally contacting some or all of thecomponents 102, 104, 106, and 108 in a pre-contactor 120. Operatingconditions for the pre-contactor 120 for step 310 can be monitored andcontrolled. Predefined amounts of components 102, 104, 106, and 108introduced into the pre-contactor 120 in step 310 can be monitored andany mixing or agitation of the components 102, 104, 106, and 108 can becontrolled within a range of selected conditions. The decision on theamount of each component 102, 104, 106, and 108 to send to thepre-contactor 120 can be decided by a PLC, DCS, or Neural Networkprogram. A controller will work to maintain the desired flow in anacceptable range. In another aspect, a set fraction or amount of eachcomponent 102, 104, 106, and 108 sent to the pre-contactor 120 can bemaintained. The bypassed amount that is not sent to the pre-contactor120, if any, will be maintained within a set range by the controlmethod, technique, or system, as described herein. Operating conditionswithin the pre-contactor 120 include, but are not limited to, residencetime, temperature, pressure, component concentration, and combinationsthereof. For example, residence time in the pre-contactor 120 in step310 for a diluent component 108 such as isobutane can be limited toapproximately 26 minutes, and the temperature within the pre-contactor120 can be maintained at approximately 100° F. (38° C.). Other suitableoperating conditions and combinations of conditions can be monitored andcontrolled, as will be apparent to those of skill in the art and are tobe considered within the scope of the present invention.

Conventional methods and devices can be used to control the range ofselected conditions. In the example above, the residence time in thepre-contactor 120 in step 310 can be controlled by adjusting the diluent108 flow into the pre-contactor 120 in step 310. Furthermore, thetemperature of the pre-contactor 120 in step 310 can be adjusted bycontrolling the amount of steam interacting with the pre-contactor 120in step 310 by utilizing a jacket or other means.

Step 315 of method 300 includes directing the components 102, 104, 106,and 108 that were sent to the pre-contactor 120 in step 310 from thepre-contactor 120 to the polymerization reactor 118. Piping, tubing, orany other suitable transfer mechanism can be used to transfer thecomponents 102, 104, 106, and 108 from the pre-contactor 120 to thepolymerization reactor 118 in step 315. The piping, tubing, or othersuitable transfer mechanism can be directed to a single or multiplelocations in the polymerization reactor 118.

Step 320 in method 300 includes directing remaining portions of thecomponents 102, 104, 106, and 108 to the polymerization reactor 118. Theremaining portions of the components 102, 104, 106, and 108 that aresent directly to the polymerization reactor 118 are those not selectedfor introduction into the pre-contactor 120 in step 310. Thus, thesecomponents are transferred directly to the polymerization reactor 118and bypass the steps 310 and 315 that involve the pre-contactor 120. Thedecision on the amount of each component 102, 104, 106, and 108 tobypass can be decided by a PLC, DCS, or Neural Network program. Asdescribed previously, the controller will work to maintain the desiredflow in an acceptable range. In another aspect, a set fraction or amountof each component 102, 104, 106, and 108 bypassed can be maintained. Thebypassed amount will be maintained within a set range by the controlmethod, technique, or system.

When the components 102, 104, 106, and 108 have been transmitted to thepolymerization reactor 118, either by step 315 or 320, the components102, 104, 106, and 108 interact to begin the polymerization process forproducing the desired polyolefin product. The polyolefin product can be,but is not limited to, homopolymers and copolymers of polyethylene andpolypropylene. The systems and processes described herein can be usedwith other polyolefins, as will be apparent to those of skill in theart.

A feedback controller can be used to measure desired properties of thepolymer and then automatically adjust the amount or ratio of components102, 104, 106, and 108 going either to the pre-contactor 120 or thereactor 118, as described herein. The desired properties include, forexample, molecular weight, molecular weight distribution, shear ratio orresponse, density, catalyst activity, rheology, melt index, or anyphysical or mechanical property deemed important to the process. Otherproperties of the polymers can be measured and used to control aspectsrelated to the components 102, 104, 106, and 108, as will be apparent tothose of skill in the art and are to be considered within the scope ofthe present invention.

Conventional methods and devices can be used to control the range ofselected conditions in the polymerization reactor 118, as previouslydescribed. In the example above, the residence time can be controlled byadjusting the flow rates of the components 102, 104, 106, and 108 intothe polymerization reactor 118. Furthermore, the solids concentrationsof the polymerization reactor 118 can be adjusted by controlling theamounts of components 102, 104, 106, and 108 reacting within thepolymerization reactor 118.

In another embodiment of the present invention, a tangible,machine-readable media is provided that includes code adapted to controlthe concentration of at least one catalyst component 102, 104, 106, 108in a mixture in the pre-contactor 120 to form the polyolefin in thepolymerization reactor 118 and code adapted to read measured values ofconcentrations and residence times in the pre-contactor 120. Themachine-readable media also includes code adapted to determine theamount of at least one catalyst component 102, 104, 106, 108 to add tothe pre-contactor 120 based on the measured values and code adapted todetermine the amount of any catalyst component 102, 104, 106, 108 tobypass the pre-contactor 120. The codes used in embodiments of thepresent invention can include separate codes for each task, such as forcontrolling a concentration of a catalyst component in a mixture in apre-contactor to form a polyolefin in a polymerization reactor.Alternatively, the codes can be combined into a single code thatcontains all of the tasks; or alternatively, subsets of codes containingone or more of the codes described herein. Examples of code that can beused to perform the tasks described herein can include computerprograms, machine-readable instructions, and the like. Suitable types ofcodes will be apparent to those of skill in the art and are to beconsidered within the scope of the present invention.

Those skilled in the art will appreciate that certain modifications canbe made to the invention herein disclosed with respect to theillustrated aspects of the invention, without departing from the scopeof the invention. And while the invention has been described above withrespect to the aspects of the invention, it will be understood that theinvention is adapted to numerous rearrangements, modifications, andalterations, all such arrangements, modifications, and alterations areintended to be within the scope of the appended claims.

The invention claimed is:
 1. A system for introduction of multiplecomponents into a polymerization system, comprising: a polymerizationcatalyst component; an activator compound component; a co-catalystcomponent; a diluent; means for adding the polymerization catalystcomponent into the polymerization system at a controlled rate; means foradding the activator compound component into the polymerization systemat a controlled rate; means for adding the co-catalyst component intothe polymerization system at a controlled rate; means for adding thediluent into the polymerization system at a controlled rate; means forintroducing the polymerization catalyst component, the activatorcompound component, the co-catalyst component, and the diluent into apre-contactor; means for agitating the polymerization catalystcomponent, the activator compound component, the co-catalyst component,and the diluent in the pre-contactor; means for directing output fromthe pre-contactor to a polymerization reactor; and wherein thepre-contactor is configured to receive a first portion of the activatorcompound component, and the polymerization reactor is configured toreceive a second portion of the activator compound component, whereinthe second portion was not sent to the pre-contactor.
 2. The system ofclaim 1, wherein the means for adding the polymerization catalystcomponent into the polymerization system at a controlled rate furthercomprises: means for selecting a desired flow rate for thepolymerization catalyst component; means for conveying thepolymerization catalyst component into the polymerization system at anactual flow rate; means for measuring the actual flow rate for thepolymerization catalyst component; and means for adjusting the actualflow rate for the polymerization catalyst component to substantiallyequal the desired flow rate for the polymerization catalyst component;wherein the means for adding the activator compound component into thepolymerization system at a controlled rate further comprises: means forselecting a desired flow rate for the activator compound component;means for conveying the activator compound component into thepolymerization system at an actual flow rate; means for measuring theactual flow rate for the activator compound component; and means foradjusting the actual flow rate for the activator compound component tosubstantially equal the desired flow rate for the activator compoundcomponent; and wherein the means for adding the co-catalyst componentinto the polymerization system at a controlled rate further comprises:means for selecting a desired flow rate for the co-catalyst component;means for conveying the co-catalyst component into the polymerizationsystem at an actual flow rate; means for measuring the actual flow ratefor the co-catalyst component; and means for adjusting the actual flowrate for the co-catalyst component to substantially equal the desiredflow rate for the co-catalyst component.
 3. The system of claim 1,comprising a means for introducing a portion of one or more of thepolymerization catalyst component, the activator compound component, theco-catalyst component into the pre-contactor; and a means for directinga remaining portion of one or more of the polymerization catalystcomponent, the activator compound component, or the co-catalystcomponent to the polymerization reactor.
 4. The system of claim 1,wherein the pre-contactor is configured to receive a portion of thepolymerization catalyst component, the co-catalyst component, and thediluent, and wherein the polymerization reactor is configured to receivea remaining portion of one or more of the polymerization catalystcomponent or the co-catalyst component that were not sent to thepre-contactor.
 5. A polymerization system configured to receive multiplecomponents comprising: a polymerization catalyst addition system storinga polymerization catalyst component and configured to add thepolymerization catalyst component to the polymerization system at acontrolled rate; an activator compound addition system storing anactivator compound component and configured to add the activatorcompound component to the polymerization system at a controlled rate; aco-catalyst addition system storing a co-catalyst component andconfigured to add the co-catalyst component to the polymerization systemat a controlled rate; a pre-contactor configured to receive a firstportion of the activator compound component and a portion of one or moreof the polymerization catalyst component or the co-catalyst component;and a first polymerization reactor configured to receive output from thepre-contactor, wherein the first polymerization reactor is furtherconfigured to receive a remaining portion of one or more of thepolymerization catalyst component or the co-catalyst component that werenot sent to the pre-contactor, and wherein the first polymerizationreactor is configured to receive a second portion of the activatorcompound component, wherein the second portion was not sent to thepre-contactor.
 6. The system of claim 5, wherein each of thepolymerization catalyst addition system, the activator compound additionsystem, and the co-catalyst addition system comprises equipment that isselected from the group consisting of a mass flow meter, a pump, avalve, and combinations thereof.
 7. The system of claim 5, wherein thefirst polymerization reactor is a CSTR, a slurry loop reactor, a batchreactor, a gas phase reactor, an autoclave reactor, a tubular reactor, amulti-zone reactor, a fluidized bed reactor, a fixed bed reactor, astirred bed reactor, a stirred fluidized bed reactor, or combinationsthereof.
 8. The system of claim 5, wherein the polymerization systemcomprises a second polymerization reactor and wherein the first andsecond polymerization reactors are arranged in a series or a parallelconfiguration.
 9. The system of claim 5, wherein the polymerizationcatalyst component comprises a polymerization metallocene solutioncomponent.
 10. The system of claim 5, wherein the activator compoundcomponent comprises a treated solid oxide compound component.
 11. Thesystem of claim 5, wherein the co-catalyst component comprises analuminum alkyl component.
 12. The polymerization system of claim 5,wherein the pre-contactor is configured for plug flow and wherein thefirst portion and the portion of one or more of the polymerizationcatalyst component or the co-catalyst component are added at an entranceof the pre-contactor and the first portion and the portion of one ormore of the or the co-catalyst component are added downstream of theentrance of the pre-contactor.
 13. The polymerization system of claim 5,wherein the polymerization catalyst component comprises between one andsix catalyst components.
 14. The polymerization system of claim 13,comprising two polymerization catalyst components including ametallocene solution.
 15. The system of claim 5, wherein thepre-contactor comprises a vessel.
 16. The system of claim 15, whereinthe vessel comprises a CSTR that includes an agitator.
 17. The system ofclaim 5, wherein the pre-contactor comprises a heating jacket configuredto heat the first portion and the portion of the one or more of thepolymerization catalyst component or the co-catalyst component.
 18. Thesystem of claim 5, comprising a diluent addition system storing adiluent and configured to add the diluent to the polymerization systemat a controlled rate, wherein the pre-contactor is configured to receivethe first portion, the portion of the one or more of the polymerizationcatalyst component or the co-catalyst component, and the diluent. 19.The system of claim 18, wherein the diluent comprises propane,isobutane, pentane, hexane, heptane, octane, or a combination thereof.20. The system of claim 18, wherein the diluent addition systemcomprises equipment that is selected from the group consisting of a massflow meter, a pump, a valve, and combinations thereof to control aresidence time of the pre-contactor.
 21. The system of claim 5,comprising a feedback controller configured to measure properties of apolymer produced in the first polymerization reactor and adjust thecontrolled rate of the polymerization catalyst component, the controlledrate of the activator compound component, or the controlled rate of theco-catalyst component.
 22. A polymerization system configured to receivemultiple components comprising: a polymerization catalyst additionsystem storing a polymerization catalyst component and configured to addthe polymerization catalyst component to the polymerization system at acontrolled rate; an activator compound addition system storing anactivator compound component and configured to add the activatorcompound component to the polymerization system at a controlled rate; aco-catalyst addition system storing a co-catalyst component andconfigured to add the co-catalyst component to the polymerization systemat a controlled rate; a diluent addition system storing a diluent andconfigured to add the diluent to the polymerization system at acontrolled rate; a pre-contactor configured to receive thepolymerization catalyst component, a first portion of the activatorcompound component, the co-catalyst component, and the diluent, whereinthe pre-contactor comprises a CSTR that includes an agitator; and afirst polymerization reactor configured to receive output from thepre-contactor, wherein the first polymerization reactor is configured toreceive a second portion of the activator compound component, whereinthe second portion was not sent to the pre-contactor.
 23. The system ofclaim 22, wherein the pre-contactor is configured to receive a portionof the polymerization catalyst component, the co-catalyst component, andthe diluent, wherein the first polymerization reactor is configured toreceive a remaining portion of one or more of the polymerizationcatalyst component or the co-catalyst component that were not sent tothe pre-contactor.